Fluid bed oxychlorination of ethylene

ABSTRACT

An oxychlorination process for the conversion of ethylene by reaction with hydrochloric acid and an oxygen-containing gas to produce a product containing at least 9 molar percent of the ethylene in the form of 1,1,2-trichloroethane and 1,1,2,2tetrachloroethane in which the gaseous reactants are passed through a reaction zone maintained at a temperature within the range of 280* to 370*C. and in the presence of a fluidized bed catalyst with the reactants present in a molar feed ratio of O2/C2H4 within the range of 0.63 to 0.9, HCl/O2 within the range of 2.60 to 4.00 and HCl/C2H4 within the range of 2.10 to 3.05, and in which the molar feed ratio of ethylene is within the range of 0.5 to 20 moles per hour per liter of catalyst with the catalyst having an average specific surface area of at least 1 m2/g.

Antonini et al.

[ Sept. 23, 1975 FLUID BED OXYCHLORINATION OF ETHYLENE [75] Inventors: Albert Antonini; Philippe Joffre,

both of Paris; Francois Laine Martiques, all of France [73] Assignee: Produits Chimiques Pechiney-Saint-Gobain, Neuilly-sur-Seine, France [22] Filed: May 27, 1971 [21] Appl. No.: 147,611

Related US. Application Data [63] Continuation-in-part of Ser. No. 730,604, May 20,

1968, abandoned.

[30] Foreign Application Priority Data May 19, 1967 France 67.106969 [52] US. Cl 260/659 A [51] Int. CL. C07'c 17/02 [58] Field of Search 260/659 A [56] References Cited UNITED STATES PATENTS 2,846,484 8/1958 Fox 260/658 R 3,598,758 8/1971 Koyanagi et al. 260/659 A 3,634,330 l/l972 Michel et a1 260/659 A 3,642,918 2/1972 Bohl et al. 260/659 A FOREIGN PATENTS OR APPLICATIONS OTHER PUBLlCATlONS Mantell, Adsorption, pp. 44, 45, 48, (1951).

Primary ExaminerDelbert E. Gantz Assistant Examiner-Joseph A. Boska [57] ABSTRACT An oxychlorination process for the conversion of ethylene by reaction with hydrochloric acid and an oxygen-containing gas to produce a product containing at least 9 molar percent of the ethylene in the form of 1,1,2-trichloroethane and 1,l,2,2-tetrachloroethane in which the gaseous reactants are passed through a reaction zone maintained at a temperature within the range of 280 to 370C. and in the presence of a fluidized bed catalyst with the reactants present in a molar feed ratio of O /C H within the range of 0.63 to 0.9, l-lCl/O within the range of 2.60 to 4.00 and HCl/C H withinthe range of 2.10 to 3.05, and in which the molar feed ratio of ethylene is within'the range of 0.5 to 20 moles per hour per liter of catalyst with the catalyst having an average specific surface area of at least 1 m /g.

11 Claims, No Drawings FLUID BED OXYCHLORINATION OF ETHYLENE This is a continuation-in-part of copending application Ser. No. 730,604, filed May 20, 1968, now abandoned and entitled. Fluid Bed oxychlorination of Ethylene.

This invention relates to the preparation of 1,2- dichloroethane, l ,l ,2-trichloroethane, 1 ,l ,2,2- tetrachloroethane and pentachloroethane by oxychlorination of ethylene in a process which makes use of a fluidized catalyst.

Processes for production of 1,2-dichloroethane by oxychlorination of ethylene in the presence of a fluidized bed catalyst are well known. Such processes have tion zone in theform of a fluid bed. Conversion rates tions which operate to reduce yield, yield undesirable I unsaturated C chlorinated compounds, and/or render separation and purification more difficult.

Thus, it is an object of this invention to provide a method and means for oxychlorination of ethylene to yield chlorinated C saturated compounds including important proportions of l,l,2-trichloroethane, l,l,2,2-tetrachloroethane and pentachloroethane in addition to 1,2-dichloroethane, in which the sum of the l,l,2-trichloroethane and 1,1,2,2-tetrachloroethane is at least9 mole percent of the transformed ethylene and preferably 1 l to 15 mole percent and which can be operated to go as high as v mole percent of the transformed ethylene.

The l,l,2-trichloroethane and the l,l,2,2- tetrachloroethane represent commercially valuable compounds which find a numberof uses alone or .as raw materialsin themariufacture of vinylidene chloride, cisand trans-dichloroethylenes and trichloroethylene. V

Applicants have achieved the aforementioned objectives with high conversion rate of ethylene and without .the parasitic reactions of combustion and dehydrochlorination exceeding 5 molar percent and 3 molar percent respectively, and preferably without exceed ing 2 molar percent for each reaction, by careful regulation of the feed ratio of reactants including hydrochloric acid, oxygen and ethylene, and careful control of reaction temperature as well as others of the reaction conditions.. A further'object of this invention resides in the combination of conditions which includes a catalytic system which makes use of a fluid bed,adefined reaction zone as well as a feed ratio of reactants, particularlythe ratio O2/C2H4- .In accordance with the oxychlorination process of this invention, a gaseous mixture of ethylene, hydrochloric acid 'and an oxygen-containing gas, preferably air, is passed'through a reaction zo ne maintained at a temperature within the range of 280 to 370C. and preferably 290 to 340C. at a molar feed rate of ethylin excess of l-lCl conversion andcombustion rate of ethylene of less than 5% are achieved when the gaseous material making up the reaction feed mixture is advanced through the reaction zone in the molar ratios of O /C H within the range of 0.63 to 0.9, HCl/Og within the' range of 2.60 to 4.30, and l-lCl/C H within the range of 2.10 to 3.05, with the preferred practice giving a conversion rate in excess of of the HCl conversion and less than about 2% combustion when the gaseous materialsmaking up the reaction mixture advanced through the reaction zone comprise the molar ratio of O /C H within the range of above 0.7 to 0.85, HCl/O within the range of 2.65 to 3.50 and l-lCl/C l-l. within the range of 2.10 to 2.65. Air has been used as a source of oxygen in the described reactions but other sources of oxygen or oxygen enriched air can be used.

With reference to the conditions described, temperature is a factor in the amount of combustion, yield of valuable chlorinated ethane compounds which I are characteristic of the nonselectivity of the reaction, as well as in the amount and type of side reactions. When a temperature in excess of 370C. is employed, side reactions become excessive and the composition exceeds practical values and excessive amounts of unsaturated compounds are produced. On the other hand, when the temperature is below 280C non-selectivity is experienced to a very slight extent, whereby little, if any, of the more highly chlorinated ethanes are produced.

The time of exposure of reaction conditions, or residence time, is of course a factor of temperature, velocity of the reaction gases through the reaction zone and catalyst. Under the conditions described, best results are secured at a residence time of from 5 to 25 seconds and'it is usually undesirable to exceed a residence time of 40 seconds. i

Similarly, within the described conditions of the reaction, some variation in product mix can be secured by variation in the reactant ratios. For example, preparation of compounds more highly chlorinated than 1,2- dichloroethane increases with increase in the molar ratio of 0 /C H in the feed. The ratio of side reactions sometimes increases with the increase in the ratio of O /C H in the feed. It has been found further that the amount of side reactions, that is combustion and dehydrochlorination, decreases with increasing ratio of HCl/O in the feed while maintaining constant the ratio O /C l-l in the feed. This provides a means within the conditions of the invention which permits an increase in the non-selectivity of the reaction while decreasing the amount of side reactions.

The applicants have established a correlation between the O /C H and l-lCl/O feed molar ratio, when air is used as gas comprising oxygen. This is to say that by setting beforehand the conversion rate of the ethylene into parasitic burning products (CO'+ CO at an upper limit'which must not-be exceeded, and which is of 5%, and preferably 2 molar percent, the molar ratio I l-lCl/O; must have values superior or equal to a limit which depends on the O IC H feed molar ratio. For inworking with a O /C H ratio of 0.70 the l-lCl/Q molar ratio must be superior or equal to 3.06. When a ratio of O /C H is fixed at 0.90, that of HCl/O must be superior or equal to 2.61.

However, in practice it is impossible to indefinitely increase the HCl/O ratio because this has for a result a total conversion rate of hydrochloric acid which becomes lower and lower as HCl/O increases, which is very seldom desirable. On the contrary, it is most often useful to perform the ethylene oxychlorination process with as high as possible a total conversion rate of hydrochloric acid, that is to say, more than 80% and preferably above 90%, such as between 90% and 96%. For instance, if a total conversion rate of hydrochloric acid of 90% is desired, and that an O /C H molar ratio of 0.70 is used, the HCl/O molar ratio must be lower or equal to 3.50. Using a /C H molar ratio of 0.90, the HCl/O molar ratio must be lower or equal to 2.92.

The following Tables I and 11 set forth the abovementioned correlation:

TABLE I Lower limit of the HCl/O molar ratio as a function of the O,/C,H molar ratio for a specified combustion rate limit of C,H..

Maximum Combustion rate (mole 5 4 3 2 O,/C,H 0.63 0.63 0.63 0.63 HCl/O, 2.83 2.90 3.01 3.22 O,/C,H, 0.7 0.7 0.7 0.7 HCl/O, 2.67 2.74 2.85 3.06 O,/C,H. 0.9 0.9 0.9 0.9 HCl/O, 2.22 2.29 2.40 2.60

TABLE II Upper limit of the HCl/O, molar ratio as a function of the O,/C,H molar ratio for a specified conversion rate of HCl.

Minimum Conversion rate of HCl 80 90 92 94 96 Oz/CJL 0.63 0.63 0.63 0.63 0.63

HCl/O; 4.30 3.70 3.58 3.45 3.36

O;/C,H 0.70 0.70 0.70 0.70 0.70

HCl/O, 4.07 3.50 3.39 3.27 3.18

0g/C1H 0.90 0.90 0.90 0.90 0.90

HCl/O: 3.36 2.92 2.83 2.74 2.66

Pressure does not have a significant effect on ratio of components in the product but it does affect productivity with increased productivity being obtained with increase in pressure. Thus, it is desirable to carry out the reaction of this invention under a pressure within the range of l to absolute bars and preferably 4 to 9 absolute bars. Absolute pressures higher than 10 bars can be used, within the limits of the equipment, but no great advantage is derived from the use of pressures greater than 10 bars.

The catalyst employed in the practice of this invention comprises a catalytic agent deposited on a carrier having an average specific surface greater than 1 m lg. and preferably greater than 10 m /g. The term average specific surface, as used herein, means that if a series of specimens are taken from different parts of the catalytic mass in order to determine the specific surface area of the carrier, in accordance with the B.E.T. method, the results of the determination will show a dispersion with the extremes within 25% of the average specific surface.

The catalyst carrier may preferably be formed of silica based mixtures containing magnesia, with the average particle size of the carrier preferably being within the range of 20 to 400 microns and most preferably 40 to 120 microns. Good results have been secured with attapulgite type clays, which consist essentially of silica and magnesia, and which, when used in the oxychlorination of this reaction, have an average specific surface within the range of 10 to 160 mlg. Very good results can by obtained with a carrier consisting essentially of synthetic mixtures of silica and magnesia having an average specific surface area within the range of 40 to 200 m lg and preferably to 160 mlg. and which exhibits excellent characteristics from the standpoint of fluidization in the fluid bed catalyst. When the upper limit of the average specific surface area is exceeded, combustion is increased and excessive amounts of catalytic cracking takes place to produce C products as well as chlorinated ethylenic C compounds.

Use can be made of catalytic agents formed of at least one compound of a metal selected from the group of alkali metals, alkaline earth metals, bismuth, cadmium, chromium, cobalt, copper, tin, iron, manganese, magnesium, platinum, rare earths, thorium, vanadium, zirconium, zinc, nickel, or mixtures thereof. Preferred catalysts employ mixtures of a copper salt and a potassium salt (e.g., copper chloride and potassium chloride).

The following examples are given by way of illustration of the practice of this invention and not by way of limitation thereof:

EXAMPLES l to 5 The oxychlorination of ethylene is carried out in a reactor made of glass having an internal diameter of 65 mm and a height of 1000 mm and heated externally by an electrical resistance. The lower part of the tube is equipped with a reversed cone filled with glass beads having a diameter of 2 mm for use as a mixing device for the reactants and to diffuse the feed gases into the catalytic bed. The height of the catalytic bed, when at rest after fluidization, is 450 mm. The catalyst is prepared by impregnating an attapulgite clay with an aqueous solution of Cl Cu, 2 H 0 and KC] in a manner such that the final content of dry catalyst, calculated in the cations of copper and potassium, is 8.7% and 4.9% by weight, respectively. The average specific surface area of the carrier, when the catalyst has been operated under normal operating conditions for about hours of reaction, is about 80 m /g. The catalytic mass has a granulometry ranging from 100 to 315 u, in which 50% of the mass has a granulometry lower than 210 u.

During the operation, the reactants, that is, ethylene, air and gaseous hydrochloric acid, are introduced under an absolute pressure of 1.05 bars into the lower portion of the reversed cone and the reactor is heated, with the external electric resistance regulating the temperature of the external wall of the tube with the aid of thermocouples placed between the external wall of the tube and the electrical resistance. The temperature of the catalytic bed is maintained constant and homogeneous at 325C. i 2C. for Examples 1 to 4 and at 350 2C. for Example 5. The products of the reaction have a composition which varies as a function of the temperature of the catalytic bed and of the feed ratio of the reactants.

Table III presents the results obtained during several thousands of hours of operation in which no variation of catalytic activity was observed during 2500 hours. in Table 111 there is also'set forth acharacteristic ratio of be noticed that the total conversion rate of ethylene and of HCl are low, that the formation of 1,1,2- trichloroethane and l.l,2,2-tetrachloroethane is extremely, low, if any. and that the formation of byhaving an average specific surface area of 0.8 m'/ g. The catalyst granulometry'or granular distribution was similar to that of the catalyst used in Examples Ho 5. It will the Obt ined results defined BS fOlI W- L 5 products of the reaction is greater than the formation of the desired product.

I 7 EXAMPLE 6 p 100 sX Y Z 2 R w-1! x y z The oxychlorlnat1on of ethylene 1s earned out 1n the 7 a v same apparatus and w1th the same catalyst as 1n Examwherein W represents the conversion rate of ethylen plesl. to-5 but w1th the catalync bed mamtamed at a into 1,2-dichloroethane; X represents the conversion temperature 0f 350 and Wlth an ethylene feed 0f rate of ethylene into 1,1,2-trichloroethahe; Y repre- =3.07'm0les/h and p lltel'iof catalyst, and a molar feed sents the conversion rate of ethylene into 1,1,2,2-

ratio of reactants /Q2 0f and OZ/CIH4 etrachlomethneg and Z g m the-conversion l5 A total rate-of convers1on of ethylene of 91.7% 1s obrate of ethylene i'nto pentachloroethane. tamed comprising! i TABLE 111 Examples NO. 1 2 5 4 5 .1 1 c Flow rule of I l C H molelh 1 and per liter ofcutulyst 1 1.93 1.21 1.07 1.00 1.84 .114 1. a 1.144 MOlfll' HC1/o. 5.27 5.10 1 2.81 2.62 3.27 5 7 5.27 3.27

feed l'ilIlO 0 6 11 0.67 0.73 0.110 0.145 067- 0.67 0.67 0.67

HCl/C H 2.19 2.26 2.25 "2.23 2.19 2.19 2.19 2.19 w 34.11 81.0 75.14. "73.0 84.0 72.5 28.2 53.1 x 7.; 10.2 11.7 12.7 7.8 1.0 0 2 0.7 Y 2.1 3.9 6.6 6.1 2.4 1.0 0.1

2 0,05,, 0.07 I 0.5 1 0.4 0.04 Conversion rate 6rc. .H. into C0 1 4 2.2 4.1 4.5 1.9 7.5 0.2 1.0 Conversion rate of CQHJ into chlorinu- 1 ted ethylenit: by l I 7 products (1.8 l.() 1.8 1.6 1.4 4 1 4.3 0.5 1.2 Total concw. 96.2 919.7 98.6 98.9 97.6 88.5 29.1 56.4

version v 1 rate of re- I actants I HCl 92.3 93.1 96.0 96.7 92.1 74 2 26.2 50.4 molar 71 a 2 I (w x Y 21 94.15 95.17 92.6v 92.2 94.24 76 5 28.4 53.9

100 (X+Y+Z) I ,7 7 l g 1 R (-WX+Y+ZI 9.9 14.9 0.. .0.8 0.9 0.7 1.5

These results show that an important proportion of -=l,2-dichloroethane 75.7 molar 1,1,2-trichl0roethane and,1,.1,2,2 tetrachloroethane is :{'jilggfigggf mag: obtained along with 1.2-dichloroethane without excesm v I 0:8 molar sive combustion or formation of su'ch by products as 5 vinyl chloride or dichloroethylenes. Y

y of p v Example lPff The formation of CO and of by-products is respec- Table f P at a temperature 5 tively 2.3% and 1.8% of the ethylene. The total converample This Illustrates yQ the temperature sion rate of hydrochloric acid is 86.1% and the ratio R limit of 370C. the yield of desirable product becomes i 13 4 lower by reason of the very rapid developmentof the combustion reaction of ethylene. in effect; this test is characterized by a' low formation of 1,1,2- I 7 EXAMPLE 7 trichloroethane and l,l,2,2-tetrachloroethane and by a total convefsionfateof y n d'O Yd An oxychlorination reaction of ethylene is carried acid far below the rates Obtained at 3 5C out in a nickel reactor having an internal diameter of By way f fu P P mpl a c of 162mm and a height of 2500 mm, externally heated by Table III Show the results Obtam d Whil rk ng Under electrical resistance coils and jacketed for cooling by conditions analogous to those of Examples 1 and 5 but the circulation of a thermal fluid through a copper coil. with a catalyst carrier having an average specific sur- At its lower portion, a perforated screen having openface area less than 1 m lg. For this purpose, use was ings of 3 mm in diameter, representing 1.2% of empty made of a catalyst prepared by impregnation, under space, is employed to distribute the gaseous reactants identical conditions asin Examples 1 to 5,211! aluminum which have previously been mixed. At its upper portion, a filtration device operates to hold back the catalyst particles which might be entrained in the gaseous streamrThe catalyst is prepared by impregnating an attapulgite clay by meansof a-solution of copper and potassium chlorides. The-particle size range (granulometry) of the prepared catalyst is 50 to 620 microns with an average of about 350 microns. The proportion of copper and potassium cations is respectively and 6% by weight of the prepared catalyst. The average specific surface area of the carrier is about 25 m /g after 500 hours of use of the catalyst. A mixture of reactants, namely, ethylene, air and hydrochloric acid, is

introduced into the reactor under an absolutepressure of 1.2 bar and in a molar ratio-of'OJC H of 0.75 and l-lCl/O of 3.0. 1

The flow ratevof'ethylene is 1.8 molesper hour per liter of catalyst/The height of the catalytic bed atrest 'is 2500 mm and the homogeneous temperature of the fluid bed is maintained at 340C.

Under these conditions the following results are obtained:

Total conversion rate of ethylene 100 Total conversion rate of hydrochloric acid 95.5% Conversion rate of ethylene into 82 1 ,Z-dichloroethane Conversion rate of ethylene into 1,1 ,2-trichloroethane 10.8% Conversion rate of ethylene into 1,1 ,2,Z'tetrachloroethane 3.8% Conversion rate of ethylene into pentachloroethane 0.1% Conversion rate of ethylene into chlorinated ethylenic compounds l.5% Conversion rate of ethylene into combustion products (C0,) l.6% Conversion rate of ethylene into chlorinated methane products 0.2% The ratio R as defined in Example 1 is of By way of comparison, Example 7 has been reproduced but with a molar feed ratio of O /C H of 0.45 and l-lCl/O of 3.

The results are the following:

Total conversion rate of ethylene 82.3% Total conversion rate of hydrochloricacid 72.3% Conversion rate of ethylene into 1,2-dichloroethane 76.2% Conversion rate of ethylene into 1,1,2-trichloroethane 2.5% Conversion rate of ethylene into 1, l ,2.2-tetrachloroethane 0.1% Conversion rate of ethylene into pentachloroethane I 0.0% Conversion rate' of ethylene into chlorinated ethylenic compounds 2.7% Conversion rate of ethylene into combustion products (C0,) 0.6% Conversion rate of ethylene into chlorinated methane products 0.2% The ratio R is only of 3.5%

The test is characterized by wholly insufticient' total conversion rate of ethylene'and hydrochloric acid and I by a very low amount of l,l,2-trichloroethane and l,l,2,2 tetrachloroethane in the product.

Alsoby way of comparison, an oxychlorination reaction was performed in accordance 'withExample 7 ex- 4 cept that the feed molar ratio of O /C l-l' of 0.70 and H Cl/O of 2.3 was employed.

Theresults secured are as'followsr" total conversion rate of ethylene -Continued Total conversion rate of hydrochloric acid Conversion rate of ethylene into l,2'-dicl'iloroethane 65.3% Conversion rate of ethylene into l. l ,2-trichloroethane 3 .7% Conversion rate of ethylene into I. l ,2.2-tetrachloroethane 0.4% Conversion rate of ethylene into pentachloroethane 0.0% Conversion rate of ethylene into chlorinated ethylenic compounds 1.7% Conversion rate of ethylene into combustion products (C0,) 1 1.1% The ratio R is only of 6.5%

It may be noted that thetotal conversion rate of ethylene is insufficient, and particularly that excessive combustion occurred. The amount of 1,1,2- trichloroethane and 1,1 ,2,2-tetrachloroethane was at a low level.

EXAMPLE 8 In the same apparatus as that of Example 7, a mixture of reactants ethylene, air and hydrochloric acid in a a molar ratio of O /C H of 0.75 and HCl/O, of 3.05 are Height of the catalyst bed, at rest:

introduced under an absolute pressure of 1.2 bars at a flow rate of ethylene of 2.3 moles per hour per liter of catalyst.

The height of the fluid bed, at rest, is 1200mm. The catalyst is the same as that of Example 7 to which 4% by weight of rare earth oxides, based upon the prepared catalyst, are added. The reaction temperature was 340C.

The results secured are as follows:

1 is of l7.5%

EXAMPLE 9 Using the same apparatus, the same catalyst and the same temperature as in Example 7, ethylene .is oxychlorinated under the following conditions:..

Press ureof reactants: I 2.5 absolute bars Molar ratio of O: in airlC H 0.80

' HCI of air: I

Flow rate of ethylene is 6.5 moles 'perhourper liter of catalyst 1200mm" Total conversion rate of ethylene 99. Total conversion rate of hydrochloric acid Conversion rate of ethylene into 1.2-dihloroethane Conversion-rate of ethylene into -Continued 2.5 absolute bars Pressure of reactants: Molar ratio of O, in air/C,H HCl of air:

. Flow rate of ethylene is 6.5 moles per hour per liter of catalyst Height of the catalyst bed. at rest:

EXAMPLE 1O Oxychlorination of ethylene is carried out in an ordinary steel reactor having an internal diameter of 240 mm and a height of 3500 mm, externally heated by electrical heating rings. At its lower portion a perforated screen having a plurality of openings of 3 mm in diameter to provide 0.4% voids is used to distribute the reagents introduced whicih have previously been mixed. Within the reactor, at a height of 600 mm, a group of 9 vertical tubes are connected transversely one to another by a thermal fluid. At its upper portion, the reactor is equipped with a system of cyclones to retain the catalyst particles entrained in the gaseous stream. The catalyst is the same as that of Example 7.

A mixture of reactants ethylene, air and hydrochloric acid are introduced into the reactor in a feed molar ratio of O /C H of 0.80 and l-lCl/O of 3.1, under an absolute pressure of 1.3 bar while the flow rate of ethylene is 1.9 moles per hour per liter of catalyst. The height of the fluidized bed, at rest, is 2600 mm and a substantially uniform temperature of 340C. is maintained throughout the bed.

Under these conditions, the results obtained are as follows:

EXAMPLE 1 1 An ordinary steel reactor consisting of a pipe havingan internal diameter of 50 cm andraheight of -600 cm is equipped at its lower portion with a screen 'perfo-v rated with 104 holes each having a'diameter'of 0.4 cm. to distribute the reactants introduced which have previously been mixed. At the inside of the reactor and at a height of 300 cm, a group of 8 vertical interconnected tubes is traversed by a thermal fluid. At the upper part of the reactor, a cyclone separator is located to return catalyst particles entrained with the gaseous stream.

The catalyst is prepared by impregnation of an attapulgite clay with a copper and potassium chloride solution. The particle size range of the prepared catalyst is 50 to 700 microns with an average size of about 330 microns. The amount of copper cations is 8% by weight and the weight ratio of Cu/l( is about 1.

The average specific surface area of the carrier, after 300 hours of operationin the oxychlorination reaction, is about 30 m lg.

The reactants ethylene, air and hydrochloric'acid are introduced into the reactor under an absolute pressure of 1.8 bars in a molar ratio of O /C H of 0.74 and l-lCl/O of 3.12. The flow rate of ethylene is 1.04 moles per hour per liter of catalyst and the height of the fluid bed is 400 cm. A uniform temperature of 340C. is maintained in the fluid bed. Under these conditions, the following results were obtained:

Total conversion rate of ethylene 95.6% Total conversion rate of hydrochloric acid 89.5% Conversion rate of ethylene into 1 ,Z-dichloroethane 81.0% Conversion rate ofethylene into 1,1,2-trichloroethane 9.0% Conversion rate of ethylene into 1.1 ,2,2-tetrachloroethane 2.7% Conversion rate of ethylene into I pentachloroethane 0.3% Conversion rate of ethylene into chlorinated ethylenic compounds 0.8% Conversion rate of ethylene into combustion products (C0,) 1.8% The ratio R as defined in Example l is of 13.

EXAMPLE 12 An oxychlorination reaction of ethylene is carried out in the same apparatus as that of Examples 1 to 5, but with a catalytic bed consisting of 1.5 liters of a catalyst prepared with silica microspheres having an average particle size of about microns and having a specific surface area of 250 m /g and impregnated with CuCl 21-1 0 and KCl solution in an amount to withhold 10% by weight of copper cations and 6% by weight of potassium cations with respect to the prepared dry catalyst.

The reactor is fed with a mixture of ethylene, l-lCl and air, with the flow rate of ethylene being .1 .24 moles per hour per liter of catalyst and in a molar feed ratio of O /C l-l of 0.73 and l-lCl/O of 3.1 1. A temperature of 322C. is maintained in the fluid bed and ethylene is converted into various compounds with the following conversion rates:

-by-products v The total conversion rates of ethylene and HCl are respectively 98.7 and 93.1%. The chlorinated ethane EXAMPLES 13 to 16 gaseous stream. The catalyst is the same as in Examples 1 to 5, except that the average particle size of said catalyst is of 140 microns instead of 210 microns.

During the operation. ethylene, air and gaseous hydrochloric acid are introduced under an absolute pressure of 7.2 bars in to the lower part of the reactor through the perforated screen. The reactor is heated Oxychlorination of ethylene is carried out with the with the external electric resistance regulating the temsame apparatus as in Examples 1 to 5 with the catalyst perature of the external wall of the tube with the aid of prepared by impregnating microspheres of a mixture of thermocouples placed between the external wall of the silica (75% by weight) and magnesia (25% by weight) tube and the electrical resistance. The temperature of with an aqueous solution of Cl Cu, 2H O and KC], so the catalytic fluid bed is maintained constant and hothat the final content of the dry catalyst in copper and mogeneous at 330C. i 2C.

potassium cations is 7% and 2.8% by weight, respec- The following table sets forth the results obtained: tively. The average specific surface area of the carrier TABLE v is of 150 m lg and remains practically unchanged in the course of normal running conditions. The particle size Examples 18 of the catalytic mass ranges from to 160 microns, 50% of this mass having a particle size lower than 100 Tale, Of 1 and per liter catalyst 9.2 9.2 microns.

The experimental conditions and results are set forth Molar feed HCl/O, 2.94 2.60 in the following table: ratio TABLE IV HCIIC H, 2.35 2.34

Temperature C. 330 330 Examples No. l3 l4 l5 [6 w 81.0 79.2 Flow rate of CH. mole/h X 8.3 9.8 and per liter of catalyst 0.75 0.75 1.71 1.23 y 35 2 0.13 0.26 Molar feed HCl/O 3.02 2.84 3.07 3.34 ratio Conversion rate of o/cni. 0.8l 0.81 0.70 0.69

HCIIC=H4 2.45 2.30 2.15 2.30 Conversion rate of CZH a a a a into chlorinated ethylenic Temperature C. 300 325 340 340 p d and c c L4 L4 W Total conversion c H 96.7 97.5 x 9.4 9.9 6.1 7.9 rate of ,eamms Y molar H01 87. 88. 2 0.1 0.1 0.1 0.1 35

2(W+X+Y+Z) 93. 93.7 Conversion rate of CgH into CO, 1.9 2.3 1.4 1.5 Ratio R as defined in Example I 12.8 15.2 Conversion rate of CJ-l into chlorinated ethylenic by-products 0.7 0.7 2.0 2.2

The characterlstlcs from the standpolnt of fluidiza- Total fonversifln 1 1 929 956 tion of the catalyst carrier in the fluid bed catalyst are 233, 31??? HC] 912 915 865 840 good but in the course of operation, these characteristics are found to be affected and therefore do not main- )Xw X Y Z) 9048 tain themselves continuously. Ratio R as defined in It will be understood that changes may be made in Example 1 13.9 16.6 11.0 13.6 the details of operation without departing from the spirit of the invention, especially as defined in the following claims.

The characteristics from the standpoint of fluldizaw l i tion of the catalyst carrier in the fluid bed catalyst are 1 A process f h Oxychlorination f ethylene to excellent. The characteristics are found to be practiproduce a product i hi h at l t 9 l percent f cally unaffected 1n the C urse f P K the ethylene is converted to l,l,2-trichloroethane and EXAMPLES l7 and 18 l,l,2,2-tetrachloroethane with not more than 5 mole percent of the ethylene converted to combustion prod- The Oxychlorination of ethylene 15 carried out In an ucts and not more than 3 mole percent of the ethylene Inconel reactor Ni y) having an mtfimal converted to chloroethylenes comprising the steps of ameter Of 120 mm and a height Of 2000 mm and heated passing a gaseous mixture of ethylene, HC] and an oxyexternally by an electrical resistance. The lower part of o t i ing g thro h a r tio zone maint ined the reactor is provided with a perforated screen having t a tem tur ithin th range f 280 t 370C, i openings of 3 mm in diameter to provide 1.2% of empty the presence of an Oxychlorination catalyst deposited space, which screen is employed to distribute the gaseon a carrier consisting essentially of silica and magnesia ous reactants which have previously been mixed. At its having" a surface area within the range of 10-200 m lg. upper portion, a filtration device operates to hold back in a fluidized state, in which the materials are advanced the catalyst particles which might be entrained in the into the reaction zone in a molar ratio of O C I-l within the range of 0.63 to 0.9, HCl/O within the range of 2.6

l to 4.30 and HCl/C2H4 within the range of 2.10 and 2. A process as defined in claim 1 wherein the carrier is selected from a group consisting of attapulgite clay having a surface area within the range of 10-160 mlg. and a synthetic mixture of silica and magnesia having a surface area within the range of 40-200 mlg.

3. A process as defined in claim 1 in which the materials are introduced in the feed ratio of o /cnig within the range of 0.7 to 0.85, HCl/O, within the range of 2.65 to 3.50, and HCl/CJ-l; within the range of 2.l to 2.65.

4. A process as defined in claim 1 in which the temperature of the reaction zone is maintained within the range of 290 to 340C.

5. A process as defined in claim 1 in which the molar feed ratio of ethylene is within the range of 0.5 to 20 moles per hour per liter of catalyst.

6. A process as defined in claim 1 in which the molar feed ratio of ethylene is within the range of 2 to 9 moles per hour per liter of catalyst.

7. A process as defined in claim 1 in which the reaction is carried out under a pressure within the range of l to 10 absolute bars.

8. A process as defined in claim 1 in which the reaction is carried out under a pressure within the range of 4 to 9 absolute bars.

9. A process as defined in claim 1 in which the gaseous reactants are in the reaction zone for a residence time up to 40 seconds.

10. A process as defined in claim 1 in which the gase ous reactants are in the reaction zone for a residence time of from 5 to 25 seconds.

11. A process for the oxychlorination of ethylene to produce a product in which at least 9 mole percent of the ethylene is converted to 1,1 ,2-trichloroethane and l,l,2,2-tetrachloroethane with not more than 5 mole percent of the ethylene converted-to combustion products and not more than 3 mole percent of the ethylene converted to chloroethylenes, comprising the steps of passing a gaseous mixture of ethylene, HCl and an oxygen-containing gas through a reaction zone maintained at a temperature within the range of 280 to 370C in the presence of a copper chloride catalyst deposited on a carrier selected from a group consisting of attapulgite clay having a surface area within the range of 10-160 mlg and a synthetic mixture of silica and magnesia having a surface area within the range of 40-200 m /g in a fluidized state, in which the materials are advanced into the reaction zone in a molar ratio of O /C H; within the range of 0.63 to 0.9, HCl/O within the range of 2.6 to 4.30 and HCl/C H; within the range of 2.10 and 3.05.

Patent No.

3, 907 912 D d September 23 1975 Inventor(s) Albert ANTONINI et al.

It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

In column 9, please delete lines 1 to 6Q [SEAL] Attest:

C. MARSHALL DANN Cmnmissioner of Patents and Trademarks RUTH C. MASON Arresting Officer 

1. A PROCESS FOR THE OXYCHLORINATION OF EHTYLENE TO PRODUCE A PRODUCT LIN WHICH AT LEAST 9 MOLE PERCENT OF THE ETHYLENE IS CONVERTED TO 1,1,2-TRICHLOROETHANE AND 1,1,2,2-TETRACHLORETHANE WITH NOT MORE THAN 5 MOLE PERCENT OF THE ETHYLENE CONVERTED TO COMBUSTION PRODUCTS AND NOT MORE THAN 3 MOLE PERCENT OF THE ETHYLENE CONVERTED TO CHLOROETHYLENES COMPRISING THE STEPS OF PASSING A GASEOUS MIXTURE OF ETHYLENE, HCL AND AN OXYGEN-CONTAINING GAS THROUGH A REACTION ZONE MAINTAINED AT A TEMPERATURE WITHIN THE RANGE OF 280* TO 370*C. IN THE PRESENCE OF AN OXYCHLORINATION CATALYST DEPOSITED ON A CARRIER CONSISTING ESSENTIALLY OF SILLICA AND MAGNESIA HAVING A SURFACE AREA WITHIN THE RANGE OF 10-200 M2/G. IN A FLUIDIZED STATE, IN WHICH THE MATERIALS ARE ADVANCED INTO THE REACTION ZONE IN A MOLAR RATIO OF O2C2H4 WITHIN THE RANGE OF 0.63 TO 0.9, HCI/02 WITHIN THE RANGE OF 2.6 TO 4.30 AND HCL/C2H4 WITHIN THE RANGE OF 2.10 AND 3.05.
 2. A process as defined in claim 1 wherein the carrier is selected from a group consisting of attapulgite clay having a surface area within the range of 10-160 m2/g. and a synthetic mixture of silica and magnesia having a surface area within the range of 40-200 m2/g.
 3. A process as defined in claim 1 in which the materials are introduced in the feed ratio of O2/C2H4 within the range of 0.7 to 0.85, HCl/O2 within the range of 2.65 to 3.50, and HCl/C2H4 within the range of 2.10 to 2.65.
 4. A process as defined in claim 1 in which the temperature of the reaction zone is maintained within the range of 290* to 340*C.
 5. A process as defined in claim 1 in which the molar feed ratio of ethylene is within the range of 0.5 to 20 moles per hour per liter of catalyst.
 6. A process as defined in claim 1 in which the molar feed ratio of ethylene is within the range of 2 to 9 moles per hour per liter of catalyst.
 7. A process as defined in claim 1 in which the reaction is carried out under a pressure within the range of 1 to 10 absolute bars.
 8. A process as defined in claim 1 in which the reaction is carried out under a pressure within the range of 4 to 9 absolute bars.
 9. A process as defined in claim 1 in which the gaseous reactants are in the reaction zone for a residence time up to 40 seconds.
 10. A process as defined in claim 1 in which the gaseous reactants are in the reaction zone for a residence time of from 5 to 25 seconds.
 11. A process for the oxychlorination of ethylene to produce a product in which at least 9 mole percent of the ethylene is converted to 1,1,2-trichloroethane and 1,1,2,2-tetrachloroethane with not more than 5 mole percent of the ethylene converted to combustion products and not more than 3 mole percent of the ethylene converted to chloroethylenes, comprising the steps of passing a gaseous mixture of ethylene, HCl and an oxygen-containing gas through a reaction zone maintained at a temperature within the range of 280* to 370*C in the presence of a copper chloride catalyst deposited on a carrier selected from a group consisting of attapulgite clay having a surface area within the range of 10-160 m2/g and a synthetic mixture of silica and magnesia having a surface area within the range of 40-200 m2/g in a fluidized state, in which the materials are advanced into the reaction zone in a molar ratio of O2/C2H4 within the range of 0.63 to 0.9, HCl/O2 within the range of 2.6 to 4.30 and HCl/C2H4 within the range of 2.10 and 3.05. 